Absorbent article having a multifunctional containment member

ABSTRACT

An absorbent article such as a diaper, training pant, and the like comprises a containment member that has a central zone and a barrier zone. The central zone has greater air flow according to the Air Permeability Test than the barrier zone. The barrier zone a greater hydrohead according to the Hydrostatic Head Pressure Test than the central zone. The containment member may be used for absorbent core formation and may have portions configured to serve as barrier leg cuffs for the finished absorbent article.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.60/811,700, filed Jun. 7, 2006, the substance of which is incorporatedherein by reference.

FIELD OF THE INVENTION

The present invention relates to absorbent articles, which are capableof absorbing bodily exudates, having a containment member with zonedcharacteristics which forms an integral barrier leg cuff.

BACKGROUND OF THE INVENTION

Absorbent articles such as diapers, training pants, incontinence briefs,and the like are well known for their convenience in absorbing andcontaining body exudates. Typical absorbent article constructioninvolves various structures having defined properties aiding the fit orfunctionality of the article. However, it is advantageous to reduce thenumber of structures and amount of material present in absorbentarticles. For disposable absorbent articles, fewer structures and lessmaterial results in reduced disposable mass. Fewer structures may alsosimplify the processing of the absorbent article. Fewer structures mayalso reduce the total cost of the absorbent article. One way to reducethe number of structures and amount of material present in an absorbentarticle is by combining the function of multiple structures into asingle structure. The core support and the barrier leg cuff are two suchstructures that may be combined.

The core support is a substrate upon which the absorbent core isdisposed. The core support typically comprises an air permeable materialsuch as a nonwoven web, a cellulosic tissue, an apertured film, or otherlike materials. The core support may assist in maintaining the integrityof the absorbent core. In particular, the cores of modern absorbentarticles comprise relatively high percentages of superabsorbent polymer(SAP) particles. Prior to liquid insult, the SAP particles oftenresemble grains of sand. The core support may be used to confine the SAPparticles within the core and to prevent the SAP particles from becomingdistributed throughout the absorbent article. Additionally, the coresupport may be a necessary component of core formation. The core supportmay serve as the formation layer upon which the components of the coreare placed during the process of forming the core. Typical corecomponents include SAP particles and cellulosic fluff. During theformation of the core, a vacuum is often drawn through the core supportso that core components disposed on the core support remain immobilized.This type of vacuum formation necessitates a core support that has arelatively high degree of air permeability, an air flow measured in, forexample, m³/m²/min, such that a vacuum may be drawn through the coresupport.

Barrier leg cuffs (e.g., also referred to as inner cuffs, inner legcuffs, leg gussets, standing leg cuffs, barrier cuffs) are physicalbarriers which inhibit loose fecal material, urine, or liquids fromescaping the article. The barrier cuffs restrain the free movement ofexudates and provide a structure to contain the exudates within thediaper. Typical barrier cuffs include a pair of flaps disposedlongitudinally on the article and running at least through the crotchregion of the article. The barrier cuffs are laterally spaced so as toallow for the receipt of body exudates into the absorbent article.Barrier cuffs typically comprise an elastic member associated with thebarrier cuff that allows the barrier cuff to stand up and serve as aphysical barrier to exudate leakage or run-off from the body-facingsurface of the article. The flaps may comprise a liquid impermeablematerial. Suitable liquid impermeable materials include materials thatare substantially or fully liquid impermeable or may be treated tobecome more liquid impermeable such as woven webs, nonwoven webs, films,and other like materials. Another consideration for flap construction isbreathability. During wear, a portion of the barrier leg cuff is incontact with the wearer. A barrier leg cuff having a breathable flap isdesirable to prevent occlusion and over hydration of the skin. The flapmay be constructed from a material that has some degree of air and vaporpermeability.

Combining the core support and the barrier leg cuff into a singlestructure requires that the structure perform different functions atdifferent locations in the diaper. For example, the single structure mayrequire, in some regions, the air permeability and SAP particleretention properties of the core support and may require, in otherlocations, the liquid impermeability and air/vapor permeability of thebarrier leg cuff. While integrating barrier leg cuffs with a substrateunderlying the core has been tried in absorbent articles (e.g., U.S.Pat. No. 5,643,239), previous executions have failed to appreciate themultiple functions that the integrated structure must exhibit.Particularly, previous applications have failed to appreciate thedynamic between high air permeability in certain zones (e.g., for coreformation) and liquid impermeability in other zones (e.g., for barrierprotection). As a result, previous executions disclose an integratedstructure that may compromise one of the functions that the structurewas intended to perform (e.g., requisite air permeability versus liquidimpermeability).

SUMMARY OF THE INVENTION

In light of the problems discussed above, the present invention relatesto a disposable absorbent article having multifunctional containmentmember that forms an integral core support and barrier leg cuff. Thepresent invention relates to an absorbent article comprising a garmentbody and an absorbent assembly joined to the garment body such that theabsorbent assembly is disposed between the garment body and a wearerduring wear. The absorbent assembly has a garment-facing surface and abody-facing surface. The absorbent assembly comprises a liquid permeabletopsheet, a containment member joined to the topsheet, and an absorbentcore disposed between the containment member and the topsheet. Thecontainment member comprises opposing upstanding edges and an elasticmember joined proximate to the upstanding edge such that the elasticmember lifts a portion of the containment member away from thebody-facing surface of absorbent assembly during wear of the absorbentarticle. The containment member comprises a central zone disposedbetween the absorbent core and the garment body and a pair of barrierzones disposed between the central zone and the opposing upstandingedges of the containment member. The central zone may have a greater airflow according to the Air Permeability Test than the barrier zone andthe barrier zone may have a greater hydrohead according to theHydrostatic Head Pressure Test than the central zone.

The present invention also relates to an absorbent article wherein thecontainment member comprises a central zone disposed between theabsorbent core and the garment body, a bond zone disposed adjacent tothe elastic member, and a barrier zones disposed between the centralzone and the upstanding edge of the containment member. The central zonemay have a greater air flow according to the Air Permeability Test thanthe barrier zone. The bond zone may have a greater hydrohead accordingto the Hydrostatic Head Pressure Test than the barrier zone.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawing, like reference numerals identify likeelements, which may or may not be identical in the several exemplaryembodiments that are depicted. Some of the figures may have beensimplified by the omission of selected elements for the purpose of moreclearly showing other elements. Such omissions of elements in somefigures are not necessarily indicative of the presence or absence ofparticular elements in any of the exemplary embodiments, except as maybe explicitly delineated in the corresponding written description.

FIG. 1 is a plan view of an exemplary, non-limiting embodiment of anabsorbent article in the form of a diaper.

FIG. 2A is a cross-sectional view, taken along the lateral centerline,of the diaper of FIG. 1 showing a central zone and barrier zones.

FIGS. 2B-C are alternate embodiments of the cross-sectional view asshown in FIG. 2A.

FIG. 3 is a plan view of a containment member such as provided in FIG.2A absent other structures prior to being incorporated in a diaper.

FIG. 4A depicts exemplary forming rolls that may be used to selectivelyincrementally stretch a containment member.

FIG. 4B is an enlarged cross-sectional view of the forming rolls of FIG.4A with a substrate therebetween.

FIG. 5 is a cross-sectional view, taken along the lateral centerline, ofthe diaper of FIG. 1 showing a central zone, barrier zones, and bondingzones.

FIG. 6 is a plan view of a containment member such as provided in FIG. 5absent other structures prior to being incorporated in a diaper.

FIGS. 7A-D are cross-sectional views of an absorbent assembly furthercomprising an impermeable member.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the following terms shall have the meaning specifiedthereafter:

“Disposable,” in reference to absorbent articles, means that theabsorbent articles are generally not intended to be laundered orotherwise restored or reused as absorbent articles (i.e., they areintended to be discarded after a single use and, preferably, to berecycled, composted or otherwise discarded in an environmentallycompatible manner).

“Absorbent article” refers to devices which absorb and contain bodyexudates and, more specifically, refers to devices which are placedagainst or in proximity to the body of the wearer to absorb and containthe various exudates discharged from the body. Exemplary absorbentarticles include diapers, training pants, pull-on pant-type diapers,refastenable diapers or pant-type diapers, incontinence briefs andundergarments, diaper holders and liners, feminine hygiene garments suchas panty liners, absorbent inserts, and the like. Absorbent articles maybe disposable or may have portions that may be restored or renewed.

“Proximal” and “Distal” refer respectively to the location of an elementrelatively near to or far from the longitudinal or lateral centerline ofa structure.

“Body-facing” and “garment-facing” refer respectively to the relativelocation of a structure or a surface of the structure. “Body-facing”implies the structure or surface of the structure is nearer to thewearer during wear than some other element or surface. “Garment-facing”implies the structure or surface of the structure is more remote fromthe wearer during wear than some other structure or surface (i.e.,structure or surface is proximate to the wearer's garments that may beworn over the disposable absorbent article).

“Longitudinal” refers to a direction running substantially perpendicularfrom a waist edge to an opposing waist edge of the article and generallyparallel to the maximum linear dimension of the article. Directionswithin 45 degrees of the longitudinal direction are considered to be“longitudinal”

“Lateral” refers to a direction running from a longitudinal edge to anopposing longitudinal edge of the article and generally at a right angleto the longitudinal direction. Directions within 45 degrees of thelateral direction are considered to be “lateral.”

“Longitudinal Centerline” refers to a longitudinal line that can bedrawn through the middle of an absorbent article. For most absorbentarticles, the longitudinal centerline separates the article into twosubstantially symmetrical halves that will fall on the left and righthalves of a wearer during wear.

“Lateral Centerline” refers to a lateral line drawn through the midpointof the longitudinal centerline and perpendicular to the longitudinalcenterline.

“Disposed” refers to an element being located in a particular place orposition.

“Joined” refers to configurations whereby an element is directly securedto another element by affixing the element directly to the other elementand to configurations whereby an element is indirectly secured toanother element by affixing the element to intermediate member(s) whichin turn are affixed to the other element.

“Extendibility” and “extensible” mean that the width or length of thecomponent can be extended or increased from a relaxed state.

“Elastic,” “elastomer,” and “elastomeric” refer to a material whichgenerally is able to extend 50% without breaking or rupturing, and isable to recover substantially to its original dimensions after thedeforming force has been removed.

“Elastomeric material” is a material exhibiting elastic properties.Elastomeric materials may include elastomeric films, scrims, nonwovens,and other sheet-like structures.

“Fine fiber” is a fiber having a denier of less than about 0.1 denier.Fine fibers may be formed by conventions means including meltblowing,electro-spinning, melt-film fibrillation, and bi- or multi-componentfiber splitting. It should be recognized that any recitation of a fiberformed by meltblowing, electro-spinning, melt-film fibrillation, orfiber splitting may be read to include fine fibers created by otherformation techniques.

“Outboard” and “inboard” refer respectively to the location of anelement disposed relatively far from or near to the longitudinalcenterline of the diaper with respect to a second element. For example,if element A is outboard of element B, then element A is farther fromthe longitudinal centerline than is element B.

“Pant” or “Pants” refers to an absorbent article having a pre-formedwaist and leg openings. A pant may be donned by inserting a wearer'slegs into the leg openings and sliding the pant into position about thewearer's lower torso. Pants are also commonly referred to as “closeddiapers,” “prefastened diapers,” “pull-on diapers,” “training pants,”and “diaper-pants.”

“Pore size” refers to the mean flow pore size as measured according toASTM method E-1294-89 (1999) entitled “Standard Test Method for PoreSize Characteristics of Membrane Filters Using Automated LiquidPorosimeter.”

“Garment body” refers to the structure of an absorbent article thatencircles the waist and legs of a wearer and maintains the position ofthe absorbent assembly while the absorbent article is in use on awearer. The garment body may also serve the function of a traditionalundergarment by providing coverage of the genitals, the buttocks, and aportion of the hips. In the absorbent article, the garment body ispositioned such that the absorbent assembly is disposed between thegarment body and the wearer during normal wear.

“Continuous substrate,” when used in reference to a containment member,means a seamless substrate (i.e., a whole material as compared to amaterial formed by joining, placing, or seaming together discretepieces).

“Laminated structure” or “laminate” means a structure in which onelayer, material, component, web, or substrate is adhesively bonded orfused, at least in part, to another layer, material, component, web, orsubstrate.

“Liquid permeable” and “liquid impermeable” refer to the penetrabilityof materials in the context of the intended usage of disposableabsorbent articles. Specifically, the term “liquid permeable” refers toa layer or a layered structure having pores, openings, and/orinterconnected void spaces that permit liquid water to pass through itsthickness in the absence of a forcing pressure. Conversely, the term“liquid impermeable” refers to a layer or a layered structure throughthe thickness of which liquid water cannot pass in the absence of aforcing pressure. Liquid impermeable materials exhibit a hydrohead of atleast about 5 mbar as measured according to the Hydrostatic Head(Hydrohead) Pressure Test provided below in the Test Methods. However,it may be desirable that a liquid impermeable material exhibit ahydrohead of at least about 10 mbar or about 15 mbar. A layer or alayered structure that is water-impermeable according to this definitionmay be permeable to vapor (i.e., may be “vapor permeable”). Such a vaporpermeable layer or layered structure is commonly known in the art as“breathable.”

“Fiber” refers to a unit of matter, synthetic or natural, characterizedby a high ratio of length-to-width. “Filament” refers to a fiber ofindefinite length

FIG. 1 is a plan view of an exemplary, non-limiting embodiment of anabsorbent article of the present invention in the form of a diaper 20.The diaper 20 is shown in a flat, uncontracted state (i.e., withoutelastic induced contraction). The body-facing surface 120 of the diaper20 is facing the viewer and the garment-facing surface 115 is away fromthe viewer. The diaper 20 includes a longitudinal centerline 100 and alateral centerline 110. The diaper 20 is shown to have a front waistregion 16, a rear waist region 18 opposed to the front waist region 16,and a crotch region 17 located between the front waist region 16 and therear waist region 18. The diaper 20 is defined by longitudinal sideedges 12 and lateral end edges 14 (which may be referred to as the waistedge). The diaper 20 may have opposing longitudinal side edges 12 thatare oriented generally parallel to the longitudinal centerline 100.However, for better fit, longitudinal side edges 12 may be curved orangled to produce, for example, an “hourglass” shape diaper when viewedin a plan view. The diaper 20 may have opposing end edges 14 that areoriented generally parallel to the lateral centerline 110; however theend edges 14 may be curved or angled to provide a more contoured diaper20.

The diaper 20 may comprise an absorbent assembly 22 joined to a garmentbody 50. The absorbent assembly 22 is disposed on the body-facingsurface of the garment body 50. During wearer, the absorbent assembly 22is disposed between the garment body 50 and the wearer. The absorbentassembly 22 may be joined to the garment body 50 via any means known inthe art. The absorbent assembly 22 may be attached to the garment body50 over substantially the entire garment-facing surface, or onlyselected regions thereof. The attachments may be substantiallypermanent, i.e., bonds such as adhesive bonds, or may be releasablyattached, i.e., via fasteners. Various other elements are known in theart and may be included in the construction of diaper 20 to improve thefit and/or functionality.

The garment body 50 is the portion of the diaper 20 that encircles thewaist and legs of a wearer. The garment body 50 serves to maintain theposition of the diaper 20 while in use on a wearer. The garment body 50also serves the function of a traditional undergarment by providingcoverage of the genitals, the buttocks, and a portion of the hips.

The garment body 50 may comprise a variety of suitable substratesincluding woven webs, nonwoven webs, polymeric films, and combinationsthereof. In certain embodiments, it may be desirable that the garmentbody 50 comprise a substrate that is substantially liquid impermeable sothat the garment body 50 may provide a containment function. Suitableliquid impermeable materials may include certain nonwovens formed toexhibit water impermeability such as nonwovens having a requisite amountof fine fibers. Suitable liquid impermeable materials also includepolymeric films, microporous films, nonwoven treated to be liquidimpermeable, and other impermeable materials known in the art.

In certain embodiments, the garment body 50 need not serve a containmentfunction, and, as a result, the garment body 50 may comprise liquidpermeable materials. In certain embodiments, the garment body 50 mayconsist essentially of a liquid permeable material (i.e., while otherliquid impermeable materials may be present in the garment body 20,these materials do not substantially affect the overall permeability ofthe garment body 20). Any suitable liquid permeable materials may beused. In particular, nonwoven and woven fibrous webs are generallydesirable for their soft, skin-pleasing character. The webs may comprisenatural and/or synthetic fibers or filaments.

In certain embodiments portions of the garment body may be or may berendered extensible or elastic in at least one direction. Suitablematerials include elastic nonwovens, elastic nonwovens laminated withextensible or elastic films or scrims, extensible nonwovens laminatedwith elastic films or scrims, elastomer patterns printed on elastic orextensible nonwovens, mechanically pre-strained variants of any of thepreceding materials, or any other elastic or extensible materials asknown in the art. Exemplary embodiments of articles incorporatingextensible or elastic garment body materials, including biaxiallystretchable materials, are described in copending application Ser. No.______ (attorney docket number 10432PQ) entitled “Absorbent ArticleHaving an Anchored Core Assembly” filed Jun. 7, 2006 in the name ofLodge et al. As shown in FIG. 1, the garment body 50 may comprise afastening system 60. When engaged, the fastening system 60 interconnectsthe front waist region 16 and the rear waist region 18 to form acircumscribing waist opening and two circumscribing leg openings. Thefastening system 60 may comprise an engaging member 62 and a receivingmember 64. The engaging member 62 may comprise hooks, loops, anadhesive, a cohesive, a tab, or other fastening mechanism. The receivingmember 64 may comprise hooks, loops, a slot, an adhesive, a cohesive, orother fastening mechanism that can receive the engaging member 62.Suitable engaging member 62 and receiving member 64 combinations arewell known in the art and include but are not limited to hooks/loop,hooks/hooks, adhesive/polymeric film, cohesive/cohesive,adhesive/adhesive, tab/slot, and button/button hole.

The garment body 50 may comprise one or more leg elastic members 72. Theleg elastic members 72 are generally disposed adjacent the longitudinalside edges 12 proximate to the leg openings. The leg elastic members 72may gather and hold the garment body 50 against the legs of the wearer.The leg elastic members 72 may aid in positioning the diaper 20 as wellas improve the aesthetics of the diaper (e.g., diaper appears more liketraditional underwear). In embodiments where the garment body 50 issubstantially liquid impermeable, the leg elastic members 72 may serve agasketing function preventing body exudates from leaking out of thediaper 20. Examples of suitable elastic members 72 include elastomericfilms, elastomeric foams such as polyurethane foams or crosslinkednatural rubber foams; formed elastic scrim; elastomeric films such asheat shrinkable elastic materials; elastomeric film laminates such as alaminate of a heat-shrinkable elastomeric film and a resilient member;and elastic strands made from rubber, synthetic rubber, elastomericpolyurethane, or other materials.

The garment body 50 may include front side panels 44 and back sidepanels 46. In certain embodiments, the front and/or back side panels 44,46 may be unitary elements of the garment body 50 (i.e., the side panelsare not separately manipulative elements secured to the garment body 50,but rather are an integral extension from the garment body 50). Thegarment body 50 for FIG. 1 includes unitary front and back side panels44, 46. In certain embodiments, the front and/or side panels may bediscrete elements that are joined to the garment body 50. Discrete frontand/or back side panels may be joined to the absorbent assembly 22 byany bonding method known in the art. The front and back side panels maybe extensible, inextensible, elastic, or inelastic. The front and backside panels may be formed from any nonwoven webs, woven webs, knittedfabrics, polymeric and elastomeric films, apertured films, sponges,foams, scrims, and combinations and laminates thereof. In certainembodiments the front and back side panels 42, 44 may be formed of anonwoven/elastomeric material laminate or a nonwoven/elastomericmaterial/nonwoven laminate. In other embodiments, the side panel 44, 46may be permanently or refastenably joined to form the pant. A suitableelastic side panel may be formed of a laminate comprising an elastomericfilm (such as supplier code X25007 from Tredegar Corp, Richmond, Va.)disposed between two nonwoven layers (such as supplier code FPN332 fromBBA Fiberweb, Brentwood, Tenn.).

In alternative embodiments, the garment body 50 may be preformed (i.e.,pre-formed waist and leg openings) by the manufacturer to create a pant.A pant may be preformed by any suitable technique including, but notlimited to, joining together portions of the article using refastenableand/or non-refastenable bonds (e.g., seam, weld, adhesive, cohesivebond, fastener, etc.). In certain embodiments, the garment body 50 maybe manufactured with the fastening system 60 engaged (i.e., the engagingmember 52 is joined to the receiving member 54). Suitable pants aredisclosed in U.S. Pat. Nos. 5,246,433; 5,569,234; 6,120,487; 6,120,489;4,940,464; 5,092,861; 5,897,545; and 5,957,908.

The absorbent assembly 22 is the portion of the diaper 20 providing muchof the absorptive and containment function. The absorbent assembly 22comprises at least a liquid permeable topsheet 24, a containment member26, and an absorbent core 28 disposed between the topsheet 24 and thecontainment member 26. It should be recognized that other structures,elements, or substrates may be positioned between the topsheet 24, core28, and/or containment member 26. As will be discussed below, suitableoptional structures include, but are not limited to, an acquisitionlayer, a distribution layer, a core wrap, or an impermeable member.Reference may be made to FIG. 2A for the following discussion onabsorbent assembly 22 construction. FIG. 2A is a cross sectional view ofthe diaper of FIG. 1 taken along the lateral centerline.

The topsheet 24 is generally a portion of the diaper 20 that may bepositioned at least in partial contact or close proximity to a wearer.Suitable topsheets 24 may be manufactured from a wide range ofmaterials, such as porous foams; reticulated foams; apertured plasticfilms; or woven or nonwoven webs of natural fibers (e.g., wood or cottonfibers), synthetic fibers (e.g., polyester or polypropylene fibers), ora combination of natural and synthetic fibers. The topsheet 24 isgenerally supple, soft feeling, and non-irritating to a wearer's skin.In certain embodiments, at least a portion of the topsheet 24 is liquidpervious, permitting liquid to readily penetrate through the thicknessof the topsheet 24. A particularly preferred topsheet 24 is availablefrom BBA Fiberweb, Brentwood, Tenn. as supplier code 055SLPV09U.

In certain embodiments, the topsheet 24 may be laterally bounded by thecontainment member 26. As will be discussed below, the containmentmember 26 comprises upstanding barrier zones 34. The topsheet 24 may bedisposed laterally between the barrier zones 34.

The topsheet 24 may be joined, by any means known in the art, to theabsorbent core 28 and/or the containment member 26. In certainembodiments, the topsheet 24 and the containment member 26 are joined byadhesive along the periphery of the absorbent core 28; this peripheryattachment may serve to encapsulate the absorbent core 28.

The absorbent core 28 has opposing longitudinal edges 29 that areoriented generally parallel to the longitudinal centerline 100. However,the longitudinal edges 29 of the absorbent core 28 may be curved orangled to produce an “hourglass” shape when viewed in a plan view. Theabsorbent core 28 has a garment-facing surface 31 a and a body-facingsurface 31 b. The absorbent core 28 may comprise a wide variety ofliquid-absorbent materials commonly used in disposable diapers and otherabsorbent articles. Examples of suitable absorbent materials includecomminuted wood pulp (e.g., air felt creped cellulose wadding); meltblown polymers including co-form; chemically stiffened, modified orcross-linked cellulosic fibers; wraps and tissue laminates; absorbentfoams; absorbent sponges; superabsorbent polymers; absorbent gellingmaterials; or any other known absorbent material or combinations ofmaterials. The absorbent core 28 may comprise a fluid acquisitioncomponent which acquires fluid exudates and partitions the exudates awayfrom a wearer's body, a fluid distribution component whichdistributes/redistributes fluid exudates points away from the point ofinitial exudate loading, and/or a fluid storage component which retainsa majority of the fluid exudates on a weight basis. A suitable absorbentcore 28 comprising an acquisition layer, a distribution layer, and/or astorage layer is described in U.S. Pat. No. 6,013,589. Other exemplaryabsorbent core configurations are discussed in U.S. Patent ApplicationPublication No. 2003/0225382A1; U.S. application Ser. No. 11/329,797,entitled, “End Seal For an Absorbent Core”, filed on Jan. 11, 2006; andU.S. application Ser. No. 11/329,796, entitled, “Sealed Core For AnAbsorbent Article”, filed on Jan. 11, 2006.

In certain embodiments, the absorbent core 28 may comprise a core wrap.The core wrap at least partially covers the liquid absorbent material ofthe absorbent core 28, but may fully encapsulate the liquid absorbentmaterial of the absorbent core 28. Typically, the core wrap is disposedon at least the body-facing surface of the absorbent core 28 between thetopsheet 24 and the core 28. The core wrap may be useful in immobilizingthe liquid absorbent material of the absorbent core 28. The core wrapmay comprise a liquid pervious substrate such as a tissue or nonwovenweb.

Another suitable absorbent core construction is described in U.S.Publication No. 2004/0167486 to Busam et al. The absorbent core of theaforementioned publication uses no or minimal amounts of absorbentfibrous material within the core. Generally, the absorbent core mayinclude no more than about 20% weight percent of absorbent fibrousmaterial (i.e., [weight of fibrous material/total weight of theabsorbent core]×100).

The containment member 26 is disposed, at least in part, adjacent to thegarment-facing surface of the absorbent core 28. The containment memberhas opposing longitudinal terminal edges 27. The containment member 26may bend inwardly away from the body-facing surface of the diaper 20 andtoward the wearer. The inward bend may be along the longitudinal edge 29of the core 28 or may be outboard of the longitudinal edge 29 of thecore 28. The containment member 26 extends to an upstanding edge 30. Incertain embodiments, the upstanding edge 30 and terminal edge 27 may becoterminous. In certain embodiments, an elastic member 36 may bedisposed along the containment member 26 proximate to the upstandingedge 30. The elastic member 36 may be joined to the containment member26 continuously or discontinuously along the length of the elasticmember 36. During wear, the elastic member 36 allows a portion of thecontainment member 26 (including a portion of the upstanding edge 30) tolift away from the body-facing surface 120 of the diaper 20 and towardthe skin of a wearer. In certain embodiments, the containment member 26may be folded over the elastic member 36 and onto itself and so as toencircle the elastic member 36. The containment member 26 may joined toitself at a bond site 38 to encapsulate the elastic member 36.

In other embodiments, the containment member 26 may be constructed tohave an elasticized region such as by having elastic filaments embeddedor woven in the containment member 26.

Examples of suitable elastic members 36 include elastomeric films,elastomeric foams such as polyurethane foams or crosslinked naturalrubber foams; formed elastic scrim; elastomeric films such as heatshrinkable elastic materials; elastomeric film laminates such as alaminate of a heat-shrinkable elastomeric film and a resilient member;and elastic strands made from rubber, synthetic rubber, elastomericpolyurethane, or other elastic materials.

The containment member 26 may comprise multiple elastic members 36. Whenmultiple elastic members 36 are present, the elastic members 36 may bedisposed proximate to each other such as shown in FIG. 2B. In analternate embodiment, multiple elastic members 36 may be disposed in aspaced relation such as shown in FIG. 2C (e.g., one elastic memberdisposed along the upstanding edge 30 and one member disposed remotelyfrom the upstanding edge 30).

The containment member 26 may comprise a central zone 32 and a pair ofbarrier zones 34. The central zone 32 is a portion of the containmentmember 26 disposed adjacent (but not necessarily in face-to-facecontact) to the garment-facing surface of the absorbent core 28. In someembodiments, the longitudinal boundary of the central zone 32 iscoterminous with the longitudinal edges 29 of the absorbent core 28.However, in other embodiments, the longitudinal boundary of the centralzone 32 may be inboard or outboard of the longitudinal edges of theabsorbent core 28. The barrier zone 34 is a portion of the containmentmember 26 disposed between the central zone 32 and the upstanding edge30. The barrier zones 34 serve as barrier leg cuffs for the absorbentassembly 22. The barrier zone 34 provides a physical barrier to the freeflow of exudates and provides a structure to contain the exudates withinthe absorbent assembly 22.

The containment member 26 may comprise a woven web, a nonwoven web, anapertured film, and a composite or laminate of any of the aforementionedmaterials. The containment member 26 may comprise a nonwoven, fibrousweb that comprises synthetic and/or natural fibers. Suitable materialsfor use in a containment member 26 include aspunbond/meltblown/meltblown/spunbond (SMMS) composite materialsavailable under supplier code MD3000 from BBA Fiberweb, Simpsonville,S.C.; SMMS composite materials available under supplier codes SM1700 andW5030 from Polymer Group, Inc., North Charleston, S.C.; a SMS compositeavailable under supplier code B3033 from Polymer Group, Inc.; and a SMScomposite available under supplier codes SM1703, SM1503, and SM1305 fromFirst Quality Nonwovens, Inc., Great Neck, N.Y.

As discussed above, the central zone 32 and the barrier zones 34 of thecontainment member 26 may exhibit distinctly different physicalcharacteristics. The central zone 32 may exhibit high air permeabilityfor absorbent core 28 formation. In certain embodiments, the centralzone 32 may exhibit an air permeability of about 100 to 300 m³/m²/min ata pressure drop of 125 Pa, preferably around 120 to 200 m³/m²/min, asmeasured according to the Air Permeability Test provided below.Conversely, it is desirable that the barrier zone 34 be liquidimpermeable; however, it is believed that the degree of air permeabilityrequired in the central zone would harm liquid impermeability.Therefore, the barrier zone 34 may exhibit an air permeability less thanthat of the central zone 32. In certain embodiments, the barrier zone 34exhibits an air permeability that is about 10%, about 20%, about 50%,about 75%, or about 100% less than the air permeability of the centralzone 32.

The barrier zone 34 may exhibit liquid impermeability for barrierprotection while maintaining air and vapor permeability for wearercomfort. In certain embodiments, the barrier zone 34 exhibits ahydrohead, as measured according to the Hydrostatic Head (Hydrohead)Pressure Test provided below, of greater than about 10 mbar, 20 mbar,and 40 mbar.

FIG. 3 depicts a plan view of a containment member 26 without elasticmembers 36 and prior to being incorporated in a diaper such as shown inFIG. 1. The containment member 26 is shown having the central zone 32and two barrier zones 34. The dotted lines represent the approximateboundary between the central zone 32 and the barrier zones 34. Whilethis embodiment depicts the boundary between the central zone 32 and thebarrier zones 34 as being linear, the boundary is not limited tostraight lines. The boundary may be curvilinear or composed ofconnecting line segments. In certain embodiments, the boundary may becoterminous with the longitudinal edge 29 of the core 28. The disparatecharacteristics of the central zone 32 and the barrier zones 34 may beachieved in a variety of ways.

In one embodiment, the containment member 26 may be composed of a firstdiscrete material that comprises the central zone 32 and a seconddiscrete material that comprises the barrier zones 34. The firstdiscrete material may be a porous nonwoven, an apertured film, or anyother suitable substrate that permits bulk air flow yet can retain orsupport particulate and/or fibrous absorbent material. The seconddiscrete material may be a liquid impermeable nonwoven such as asubstantially liquid impermeable nonwoven as known in the art.Additionally, the second discrete material may comprise a microporousfilm. The second discrete material may be a woven or nonwoven treated tobe liquid impermeable. The first discrete material may be joined to thesecond discrete material by a bonding method well known in the art suchas by adhesives; fusion bonding such as by heat, pressure, or ultrasonicwaves; and the like. It should be recognized that the first and secondmaterials may overlap each other in the regions where they are bondedtogether.

In the embodiments that follow, the containment member 26 may comprise acontinuous substrate that forms the central zone 32 and the barrierzones 34. The continuous substrate may be formed, modified, or treatedto yield zoned properties.

In one embodiment, the containment member 26 may be formed withlaminated or composite regions that provide zoned properties. Forexample, the containment member 26 may comprise aspunbond/meltblown/spunbond (SMS) composite in the barrier zones 34white the spunbond layers extend into and form the central zone 32 suchthat no fine fibers or a lower basis weight of fine fibers than arepresent in the barrier zones 34. In another example, the containmentmember 26 may comprise a nonwoven web having a secondary substrate(e.g., a polymeric film or other liquid impermeable material) laminatedin the barrier zones 34. The secondary substrate may be joined to thenonwoven using conventional bonding means such as an adhesive or fusionbonding. The secondary substrate may be air and vapor impermeable orpermeable. In one particular execution, the containment member 26 maycomprise a spunbond web having a basis weight of approximately 10 gsm.The barrier zones 34 may further comprise strips of an SMS composite webadhesively joined to the spunbond web.

In another embodiment, the containment member 26 may be constructed withvarying pore sizes in the central zone 32 versus the barrier zone 34.The containment member 26 may be constructed such that the central zone32 comprises pores with a larger average size than those of the barrierzones 34. The containment member 26 may be formed with an increasedbasis weight of fine fibers in the barrier zones by depositing finefibers only in those zones during the nonwoven formation process (e.g.,only have meltblown heads active in those regions of the nonwovenformation beam).

In particular embodiments, the central zone 32 may comprise pores havingan average pore size of about 35 to about 50 microns or, alternately, ofabout 40 to about 45 microns. The barrier zone 34 may comprise poreshaving an average pore size of about 1 to about 30 microns. However, insome executions, the barrier zone 34 may be substantially pore-free.

In certain embodiments, the containment member comprises a substratehaving pores in the central zone having a first average pore size andhaving pores in the barrier zone having a second average pore size. Thefirst average pore size may be about 20%, 50%, 75%, or, alternately,100% greater than the second average pore size.

Construction of a substrate having variable pore size may be performedby any of the substrate formation (e.g., basis weight or deniermodification) or substrate deformation (e.g., mechanical deformation)techniques discussed below. For example, a microporous web may be formedby stretching a polymeric film containing a pore forming agent (e.g.,calcium carbonate or other relatively inert inorganic particulatematerial). As the film is stretched, the film separates from the poreforming agents thereby creating micropores. The size of these pores canbe controlled to some extent by the degree of extension applied to thefilm. As a result, with increased elongation, larger pores may be formedin the central zone 32 of the containment member 26. Further discussionof microporous film formation is provided in U.S. Pat. No. 6,605,172.

In another embodiment, the relative degree of air permeability andliquid permeability may be controlled by adjusting the basis weight ofthe material comprising the respective zones. Particularly for nonwovenmaterials, decreased basis weight results in increased air permeabilityand water permeability. A containment member 26 constructed from anonwoven may have a zoned basis weight such that the basis weight of thecentral zone 32 is less than the basis weight of the barrier zone 34. Azoned basis weight nonwoven may be formed by conventional lay-downtechniques including spunbonding, meltblowing, carding, and air laying.In one suitable execution, a nonwoven web with zoned basis weight can beformed by selectively blocking apertures of the spunbond die or bydeflecting the lay-down of the formed filaments. In another suitableexecution, a composite SMS nonwoven web may be formed such that thebasis weight of the meltblown layer varies from the central zone 32 tothe barrier zone 34. For example, a SMS web may be formed such that eachof the outer layers comprise about 5-6 gsm of spunbond filaments and theinner layer comprises about 0-1.5 gsm of meltblown fibers in the centralzone versus about 1-5 gsm of meltblown fibers in the barrier zone. Inanother suitable execution, the collector belt (i.e., the web upon whichnonwoven webs such as spunbond and meltblown web may be formed) maycomprise zones of higher permeability and lower permeability which mayresult in a web having higher basis weight and lower basis weight,respectively. Alternately, the collector belt may be subjected tovarying degrees of vacuum with high vacuum areas (i.e., greater suction)resulting in higher basis weights.

In other embodiments, the relative degree of air permeability and liquidpermeability may be controlled by adjusting the denier of the fibersand/or filaments used to construct the containment member 26. It isgenerally recognized that, given equal basis weights, a nonwoven webcomprised of larger denier fibers or filaments will be more air andliquid permeable than a nonwoven web comprised of smaller denier fibers.A containment member 26 constructed from a nonwoven may have a zoneddenier such that the denier of the fibers and/or filaments of thecentral zone 32 is greater than the denier of the fibers and/orfilaments of the barrier zone 34. As a result, the central zone 32 mayexhibit greater air permeability compared to the barrier zone 34, andthe barrier zone 34 may exhibit greater liquid impermeability comparedto the central zone 32. The preceding paragraph, describes a suitableembodiment of a nonwoven web having fine fibers in the barrier zone 34and little to no fine fibers in the central zone 32 (e.g., SMS compositewith meltblown fibers present in the barrier zone 34 but not in thecentral zone 32). Fiber denier may also be tailored by using splitablemulti-component fibers (which include bicomponent fibers). Themulti-component fibers may be spun with a particular geometry (e.g.,segmented pie, hollow segmented pie, tipped trilobal, or striated) thatfacilitates division of the fiber into smaller subfibers uponapplication of an activator (e.g., mechanical energy, humidity, etc.).The multi-component fibers may be spun with a particular geometry suchas an islands-in-the-sea configuration such that subfibers (e.g.,islands) are created upon removal of the encasing component (e.g., sea)by means known in the art. In certain embodiments, the denier of thefibers comprising the central zone 32 and the barrier zone 34 may differby more than about 20%, 50%, 100%, 250%, or 500%.

In other embodiments, the relative degree of air permeability and liquidpermeability may be controlled by adjusting the cross-sectional shape ofthe fibers and/or filaments used to construct the containment member 26.Fibers that do not have a substantially round cross-sectional shape(e.g., trilobal, delta, bilobal, etc.) create more air drag. As aresult, a web comprising substantially non-round fibers may have reducedair permeability compared to a web of equal denier and basis weightcomprising round fibers. In a suitable embodiment, a nonwoven web may beconstructed with one zone comprising predominately (greater than 50%based on number of filaments) round (e.g., circular or elliptical)cross-sectional shaped filaments and with another zone comprisingpredominately (greater than 50% based on number of filaments) non-round(e.g., trilobal, bilobal, delta, etc.) cross-sectional shaped filaments.Such zoned shaped webs can be formed by, for example, a spunbond diehaving apertures of differing shapes.

In other embodiments, the relative degree of air permeability of thecentral zone 32 of the containment member 26 can be controlled by avariety of mechanical deformation techniques that form pores in asubstrate or that increase the size of pores or interstices in asubstrate or that transform an impermeable substrate into a permeablesubstrate. Suitable techniques for pore or aperture formation includethe use of needle punches, fluid jet streams, laser aperturing, knife orslitting rolls, and other techniques well known in the art. In oneembodiment, a laser may be used to selectively aperture a polymeric filmthat may then become a component of the containment member 26. Apolyolefinic film having a basis weight of about 10-30 gsm may be used.Laser aperturing allows for greater precision and replication inaperture formation. The apertured region may then be disposed in thecentral zone 32 where greater air permeability is desired.

In other embodiments, the zoned properties of the central zone 32 andthe barrier zones 34 may be provided by selective mechanical weakeningof the containment member 26. Mechanical weakening may result in poreformation in substrates where pores were not initially present.Mechanical weakening may result in increased pore size or interstices insubstrates where pores or interstices were initially present. Mechanicalweakening may be performed by stretching or tentering by pulling the webover a laterally curved surface. Alternatively, mechanical weakening maybe performed by incrementally stretching one or more portions of thecontainment member 26. Incremental stretching may be performed bypassing a substrate or portions of a substrate through two corrugatedinterengaging rolls 210, 212 at a nip 240 known as “ring rolling.”Exemplary forming rolls 210, 212 are shown in an enlarged perspectiveview in FIG. 4A. The rolls 210, 212 may include a plurality ofaxially-spaced, side-by-side, circumferentially-extending,equally-configured teeth 220, respectively, that can be in the form ofthin fins of substantially rectangular cross section, or they can have atriangular or an inverted V-shape when viewed in cross section. Theoutermost tips of the teeth 220 may be rounded to avoid cuts or tears inthe substrate that pass between the rolls.

The spaces between adjacent teeth 220 define recessed,circumferentially-extending, equally configured grooves 222. The grooves222 can be of any suitable shape so as to accept engagement of the teeth220. Typically, the shape of the groove is substantially similar to theshape of the teeth 220. FIG. 4B is an enlarged cross-sectional view ofinterengaged teeth 220 and grooves 222 forming nip 240 with a substrate230 being modified therebetween. The interengagement of the teeth 220and grooves 222 of the rolls 210, 212 causes laterally spaced portionsof the substrate 230 to be pressed by teeth 220 into opposed grooves222. In the course of passing between the forming rolls 210, 212, theaction of the teeth 220 pressing the substrate 230 into opposing grooves222 exerts a tensile stresses on the substrate that result inelongation. The tensile stresses cause intermediate portions 232 of thesubstrate 230 that lie between and span the spaces between the tipportions of adjacent teeth 220 to stretch or extend, which results in alocalized reduction of the web thickness. When nonwoven or woven websare subjected to incremental stretching, individual filaments and/orfibers are detangled, separated, and/or elongated leaving striped areasof lower basis weight.

Incremental stretching is particularly suited for creating zonedproperties in the containment member 26 since forming rolls can beconfigured in a variety of ways such that certain zones of thecontainment member 26 may experience significant elongation forces whileother zones may experience little to no elongation forces. For example,the forming rolls may have interengaging teeth and grooves along only aportion of the total width of the rolls. Such a roll configuration wouldyield a substrate having an incrementally stretched zone (i.e., theportion of the substrate passed through the teeth and grooves) and oneor more zones that are unstretched (i.e., the portions of the substratenot passed through the teeth and grooves). In one embodiment, thecontainment member 26 may comprise a suitable nonwoven substrate whereina region of the substrate has been incrementally stretched by 10 to 50%of that region's initial width. This incrementally stretch region may bedisposed in the central zone 32 to provide greater air permeability thanthe non-stretched regions that may form the barrier zones 34.

Further discussion regarding methods for imparting elasticity to anextensible or otherwise substantially inelastic material by usingcorrugated interengaging rolls which incrementally stretch in themachine and/or cross-machine direction and permanently deform thematerial is provided in U.S. Pat. Nos. 4,116,892; 4,834,741; 5,143,679;5,156,793; 5,167,897; 5,422,172; 5,518,801; and 6,383,431.Alternatively, incremental stretching of the printed carrier web 12 maybe performed by a pair of interengaging grooved planar plates or othermeans for incremental stretching (i.e., not rolls) the carrier web 12.Incremental stretching is suitable for a containment member 26comprising a nonwoven web, woven web, microporous film, or a precursormicroporous film (e.g., a polymeric film containing a pore forming agentsuch as calcium carbonate).

In the embodiments that follow, a relatively air permeable substrateforming the containment member 26 may be treated or modified to improvethe liquid impermeability of the barrier zones 34. While the followingtreatment and modification techniques may be applicable to allsubstrates, the techniques are particularly applicable to fibrous wovenand nonwoven webs. One such method for improving the liquidimpermeability of the barrier zones 34 is by applying a chemicaltreatment that fills in pores and reduce overall pore size distributionor that decrease the surface energy of portions of the containmentmember 26. Suitable hydrophobic surface treatments are known in the art.Particularly suitable hydrophobic surface treatments include siliconeliquids, waxes, and polymers (such as silicone resins,polydimethysiloxanes, crosslinked silicones, silicone liquid elastomers)and fluorinated polymers (such as telomers and polymers containingtetrafluoroethylene and/or perfluorinated alkyl chains). Hydrophobicskin care compositions, such as those disclosed in U.S. Pat. Nos.5,635,588 and 5,643,588, may also be employed to reduce liquidpermeability of the barrier zones. Barrier coatings may be used such asthose described in U.S. Publication No. 2005/0256476A1. Other suitablehydrophobic surface treatments are discussed in U.S. Publication No.2005/0177123A1. The surface treatments may be selectively applied to thematerial forming the containment member 26 by conventional meansincluding spraying, slot-coating, immersion, reverse rolls, gravurerolls, and curtain coating.

In other embodiments, the relative liquid permeability of the barrierzones 34 may be altered through the use of high energy surfacetreatments. Exemplary high energy surface treatments include but are notlimited to corona discharge treatment, plasma treatment, UV radiationtreatment, ion beam treatment, electron beam treatment, and certainlaser treatments including pulsed lasers. The surface energy of selectzones of the containment member 26 can lowered (i.e., resulting inincreased hydrophobicity) by conducting the high energy surfacetreatment in an appropriately chosen atmosphere. For example, thebarrier zones 34 of the containment member 26 may be subjected to plasmatreatment in a methane atmosphere. Such treatment is particularlyeffective when the containment member 26 comprises a substantiallyhydrophilic substrate such as a woven or nonwoven including cellulosicfibers.

In other embodiments, the relative liquid permeability of the barrierzones 34 may be altered through the use of barrier coatings.Particularly for porous substrates such as woven and nonwoven webs, acoating may be applied that serves as an impediment to liquidpenetration. The barrier zones 34 of the containment member 26 may becoated with wax, an adhesive, or a composition that is capable offorming a liquid impermeable film. Suitable barrier coatings andtechniques are further described in U.S. Publication Nos. 2003/0065298A1and 2002/0035354A1 as barrier structures.

In other embodiments, the relative liquid permeability of the barrierzones 34 may be altered by physically deforming the containment member26 to reduce or eliminate pores. For example, a polymeric nonwoven suchas a polyolefin spunbond web may be of subjected to compression and/orheat. The nonwoven may be compressed so as to consolidate theconstituent fibers or filaments thereby reducing the pore size. Thenonwoven may be heated to a point where the polymer fibers or filamentsare softened. Individual fibers or filaments may meld together therebyreducing pore size. Both heating and compression may be applied such asby subjecting the containment member 26 to a heated nip. It should berecognized that compression and heating may also be effective inimproving the water impermeability of other materials such a microporousfilms. For example, a nonwoven web such as a spunbond or carded web maybe selectively subjected to an engraved calendar roll which results inlocalized bonds where the fibers have been fused together. By increasingthe number and/or area of the bonds within a region, the airpermeability of that region may diminish while the liquid impermeabilitymay be improved. A nonwoven web with varying bond area and/or number maybe a component of the containment member 26 such that the region havinga greater bond area and/or number is disposed in the barrier zone 34.

It may be desirable for the containment member 26 to contain more thantwo zones exhibiting distinctly different physical characteristics. FIG.5 is a cross sectional view of an absorbent assembly 22 taken along alateral centerline. The absorbent assembly 22 of FIG. 5 is substantiallysimilar to that shown in FIG. 2A; however, the containment member 26 isshown to have three zones: a central zone 32, barrier zones 34, and bondzones 40. The bond zone 40 is the portion of the containment member 26utilized in the attachment or joining of the elastic member 36. In someembodiments, the bond zone 40 may be defined as the portion of thecontainment member 26 to which the elastic member 36 is joined. In otherembodiments, such as the one shown in FIG. 5, the bond zone 40encompasses the portion of the containment member 26 that is folded overand bonded to itself. In this embodiment, the bond zone 40 extends fromthe upstanding edge 30 to the inboard edge of the bond site 38. However,in other embodiments, the bond zone 40 is delineated by a change incontainment member 26 characteristics from the barrier zone 34 and/orthe central zone 32.

FIG. 6 depicts a plan view of a containment member 26 without theelastic member 36 and prior to being incorporated into the absorbentassembly 22 as shown in FIG. 5. The containment member 26 is shownhaving the central zone 32, two barrier zones 34 laterally outboard ofthe central zone 32, and two bond zones 40 laterally outboard of thebarrier zones 34. The dotted lines represent the approximate boundarybetween the central zone 32 and the barrier zones 34 and between thebarrier zones 34 and the bond zones 40. While this embodiment depictsthe boundary between the central zone 32, the barrier zones 34, and bondzones 40 as being linear, the boundary should not be limited straightlines. The boundary may be curvilinear or composed of connecting linesegments.

The bond zone 40 may have characteristics different from those of thecentral zone 32 and/or the barrier zones 34. Internal surfaces of thebond zone 40 may be coated with adhesive which serves to form the bondsite 38 and/or the attachment of the elastic member 36 directly to thecontainment member 26. Therefore, it may be desirable that the bond zone40 have improved resistance to adhesive bleed through (adhesivepenetrating pores or interstices in the containment member 26).

Typically, during manufacture, molten adhesive is applied to a portionof the containment member 26. The adhesive bearing portion of thecontainment member 26 may be folded over an elastic member 36 such as isshown in FIG. 5. The bond site 38 may be subjected to a nip roll orother pressure inducing mechanism which aids the adhesiveinterconnection. However, the nip roll may exert a pressure that canpush the adhesive through the pores or interstices of the containmentmember 26. This is commonly referred to as “bleed-through” and isundesirable. One way to reduce adhesive bleed through is by reducing thepore size or volume of the interstices in the containment member 26.Several methods for varying pore size have been discussed above inregard to the central zone 32 and the barrier zones 34; these methodsare equally applicable to varying the pore size or interstitial volumeof the bond zone 40.

In certain embodiments, the central zone 32 may have a greater air flowthan the barrier zone 34 and the barrier zone 34 has a greater air flowthan the bond zone 40. In other embodiments, the air permeability of thecentral zone 32 is about 10% greater than that of the barrier zone 34and the air permeability of the barrier zone 34 is about 10% greaterthan that of the bond zone 40. Additionally, the bond zone 40 may have agreater hydrohead than the barrier zone 34 and/or the central zoned 32.

Furthermore, any treatment or modification applied to the bond zone 40should not adversely impact the function of the adhesive. As a result,hydrophobic surface treatments and barrier coatings such as waxes orfilm formers may present on the adjacent barrier zone 34 but may, insome instances, be disfavored on the bond zone 40.

Returning to the construction of the absorbent assembly 22, otheroptional structures may be present in the absorbent assembly. FIG. 7A-Dillustrate embodiments of the absorbent assembly further comprising animpermeable member 55. The impermeable member 55 may be any suitablesubstrate that is substantially liquid impermeable by itself or, in asituation where the impermeable member 55 is joined to anothersubstrate, that renders the resulting laminate substantially liquidimpermeable. Ideally, the impermeable member 55 will exhibit air and/orvapor permeability. Suitable materials for use as the impermeable member55 include woven webs, nonwoven webs, polymeric films, microporousfilms, and composites and laminates thereof. The impermeable member 55may be joined to the absorbent assembly by any conventional bondingtechnique such as by an adhesive, pressure bonds, or heat bonds.

In certain embodiments it is desirable that the overall size of theimpermeable member 55 be minimized. Even in executions where theimpermeable member 55 is air and/or vapor permeable, the liquidimpermeability of the member 55 generally limits the amount of airand/or vapor permeability that can be exhibited. Therefore, to achievemaximum air and/or vapor permeability the size of the impermeable member55 may be minimized. In certain embodiments, the impermeable member 55is within the central zone 32 (i.e., impermeable member 55 does notextend beyond the central zone 32). In other embodiments, theimpermeable member 55 is bounded by the upstanding edge 30 or terminaledge 27, as shown in FIG. 5. In other embodiments, the impermeablemember 55 is coterminous with the containment member 26 or is bounded bythe containment member 26 (i.e., does not extend beyond the terminaledges 27 of the containment member 26 in a plan view such as shown inFIG. 3).

FIGS. 7A-B depict absorbent assemblies having the impermeable member 55disposed adjacent the garment-facing surface of the containment member26. In FIG. 7A, the impermeable member 55 is laterally bounded withinthe central zone 32. In FIG. 7B, the impermeable member 55 is laterallybounded by the containment member 26. FIGS. 7C-D depict absorbentassemblies having the impermeable member 55 disposed between thecontainment member 26 and the absorbent core 28. In FIG. 7C, theimpermeable member 55 is laterally bounded within the central zone 32.In FIG. 7D, the impermeable member 55 is laterally bounded by thecontainment member 26.

Test Methods Air Permeability

Air permeability is determined by measuring the time in which a standardvolume of air is drawn through a test specimen of a defined area at aconstant pressure and temperature. This test is particularly suited tomaterials having relatively high permeability to gases, such asnonwovens, apertured films and the like. The air permeability test isperformed according to ASTM D737-96 entitled “Standard Test Method forAir Permeability of Textile Fabrics” with the following test parameters.A TexTest FX3300 instrument is used. (Available by Textest AG inSwitzerland (www.textest.ch), or from Advanced Testing Instruments inSpartanburg S.C., USA.) The test is conducted in a laboratoryenvironment at about 22±2° C. and about 50% relative humidity. The testpressure drop is 125 Pascal and the test area is 38 cm². In this test,the instrument creates a constant differential pressure across thesample which draws air through the sample. The rate of air flow throughthe sample is measured in ft³/ft²/min (often called cfm or ft/min) orm³/m²/min (or m/min). For each sample, three replicates should be run,and the average result is reported.

Hydrostatic Head (Hydrohead) Pressure

The property determined by this test is a measure of the liquid barrierproperty (or liquid impermeability) of a material. Specifically, thistest measures the hydrostatic pressure the material will support: when acontrolled level of water penetration occurs. The hydrohead test isperformed according to EDANA 120.2-02 entitled “Repellency: HydrostaticHead” with the following test parameters. A TexTest Hydrostatic HeadTester FX3000 (available from Advanced Testing Instruments, Corp.,Spartanburg, S.C., or by Textest AG in Switzerland (www.textest.ch)) isused. For this test, pressure is applied to a defined sample portion andgradually increases until water penetrates through the sample. The testis conducted in a laboratory environment at about 22±2° C. temperatureand about 50% relative humidity. The sample is clamped over the top ofthe column fixture, using an appropriate gasketing material (o-ringstyle) to prevent side leakage during testing. The area of water contactwith the sample is equal to the cross sectional area of the watercolumn, which equals 28 cm². Water is pumped into the water column at arate of 20 mbar/min. Thus, the sample is subjected to a steadilyincreasing water pressure on one surface. When water penetration appearsin three locations on the other surface of the sample, the pressure(measured in mbar) at which the third penetration occurs is recorded. Ifwater immediately penetrates the sample (i.e., the sample provided noresistance), a zero reading is recorded. For each material, threespecimens are tested and the average result is reported.

Basis Weight

Basis weight can be measured consistent with compendial methods EDANAERT-40.3-90 entitled “Mass per Unit Area” with the test parameters thatfollow. Basis weight is defined as mass per unit area, with grams persquare meter (often called gsm rather than g/m²) as the preferred unit.Required instruments are a scissors or a die-cutter for sample cuttingand an accurate weighing device (scale). A sample is cut to a total areaof 100 cm² per layer with an accuracy and precision of ±0.5%. A scale orbalance is needed with 0.001 g sensitivity, readable, calibrated andaccurate to within 0.25% of the applied load. The samples areconditioned at 23° C. (±2° C.) and at a relative humidity of about 50%for 2 hours to reach equilibrium. Weigh the cut sample with 10 pliesfrom the sample area for a total of 1000 cm²=0.1 m² on an analyticalbalance to the nearest 0.001 g and record the weight. (For samplesthicker than 1 mm, weighing only 1 ply is preferred but should be notedif done so.) Calculate the basis weight by dividing the weight by thesample area (all layers tested) to give the basis weight in gsm. Alldata are recorded for statistic analysis.

Fiber Diameter (and Denier)

Fiber diameters are determined by using a Scanning Electron Microscope(SEM) and image analysis software. A magnification of 500 to 10,000 ischosen such that the fibers (or filaments) are suitably enlarged formeasurements. Image analysis software for automatic sampling of fiberdiameter in the SEM picture is possible, but also a more manualprocedure can be used. In principle the edge of a randomly selectedfiber is sought and then measured across the width (perpendicular tofiber direction at that spot) to the other edge of the fiber. A scaledand calibrated image analysis tool provides the scaling to get theactual reading in meter or mm or micrometers (μm), e.g. Several fibersor filaments are thus randomly selected across the sample of web in theSEM. Typically several samples from a web are cut and tested in thismanner. Altogether at least about 100 such measurements are made and alldata are recorded for statistic analysis. If the result is to berecorded in denier, then the following calculation needs to be made.Diameter in denier=Cross-sectional area×density×9000 m×1000 g/kg. Thecross-sectional area is π×diameter²/4. The density for PP, e.g., can betaken as 910 kg/m³. To obtain decitex (dtex), instead of using 9000 m,use 10,000 m.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any definitionor meaning of a term in this written document conflicts with anydefinition or meaning of the term in a document incorporated byreference, the definition or meaning assigned to the term in thisdocument shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

1) An absorbent article comprising a garment body and an absorbentassembly joined to the garment body such that the absorbent assembly isdisposed between the garment body and a wearer during wear, wherein saidabsorbent assembly has a garment-facing surface and a body-facingsurface, wherein said absorbent assembly comprises: a) a liquidpermeable topsheet, b) a containment member joined to the topsheet, andc) an absorbent core disposed between said containment member and saidtopsheet, said absorbent core having opposing longitudinal edges;wherein the containment member comprises opposing upstanding edges andan elastic member joined proximate to the upstanding edge such that saidelastic member lifts a portion of the containment member away from thebody-facing surface of the absorbent assembly during wear of theabsorbent article, wherein the containment member comprises: i) acentral zone disposed between the absorbent core and the garment body,ii) a pair of barrier zones disposed between the central zone and theopposing upstanding edges of the containment member, wherein the centralzone has a greater air flow according to the Air Permeability Test thanthe barrier zone and the barrier zone has a greater hydrohead accordingto the Hydrostatic Head Pressure Test than the central zone. 2) Theabsorbent article of claim 1 wherein the central zone has air flow,according to the Air Permeability Test, about 10% greater than that ofthe barrier zone. 3) The absorbent article of claim 1 wherein thecontainment member comprises a substrate having first pores in thecentral zone having a first average pore size and second pores in thebarrier zone having a second average pore size, wherein the firstaverage pore size is about 20% greater than the second average poresize. 4) The absorbent article of claim 3 wherein the barrier zone ofthe containment member has been heated, compressed, or both to reducethe size of the second pores. 5) The absorbent article of claim 1wherein the containment member comprises a substrate having a basisweight in the central zone less than the basis weight in the barrierzone. 6) The absorbent article of claim 1 wherein the containment membercomprises a fibrous nonwoven. 7) The absorbent article of claim 6wherein the fibrous nonwoven comprises first fibers in the central zoneand second fibers in the barrier zone; wherein the first fiberspredominately have a first cross-sectional shape, wherein the secondfibers predominately have a second cross-sectional shape, and whereinthe first cross-sectional shape is different from the secondcross-sectional shape. 8) The absorbent article of claim 6 wherein thefibrous nonwoven comprises first fibers in the central zone having afirst denier and second fibers in the barrier zone having a seconddenier; wherein the first denier is different from the second denier. 9)The absorbent article of claim 6 wherein a secondary substrate is joinedto the fibrous nonwoven such that the secondary substrate issubstantially disposed in the barrier zone. 10) The absorbent article ofclaim 9 wherein the secondary substrate is liquid impermeable. 11) Theabsorbent article of claim 6 wherein the nonwoven comprises fine fibersin the barrier zone and, optionally, in the central zone such that thebarrier zone comprises a greater basis weight of fine fibers than doesthe central zone. 12) The absorbent article of claim 1 wherein thecentral zone of the containment member is mechanically treated toincrease air permeability, wherein the mechanical treatment is selectedfrom a group consisting of perforating, laser apeturing, fluid jetaperturing, incremental stretching, ring rolling, tentering, generalstretching or combinations thereof. 13) The absorbent article of claim 1wherein the barrier zone of the containment member is coated with ahydrophobic surface coating or a barrier coating and wherein the centralzone is substantially free of the hydrophobic surface coating or barriercoating. 14) The absorbent article of claim 1 wherein the barrier zoneexhibits a lower surface energy than does the central zone. 15) Theabsorbent article of claim 1 wherein the absorbent article furthercomprises an impermeable member disposed between the absorbent assemblyand the garment body. 16) The absorbent article of claim 1 wherein theabsorbent assembly further comprises an impermeable member disposedbetween containment member and the absorbent core. 17) The absorbentarticle of claim 1 wherein the garment body consists essentially of aliquid permeable substrate. 18) The absorbent article of claim 1 whereinthe containment member comprises a continuous substrate. 19) Theabsorbent article of claim 1 wherein the containment member comprises acomposite substrate or laminate substrate. 20) An absorbent articlecomprising a garment body and an absorbent assembly joined to thegarment body such that the absorbent assembly is disposed between thegarment body and a wearer during wear, wherein said absorbent assemblyhas a garment-facing surface and a body-facing surface, wherein saidabsorbent assembly comprises: a) a liquid permeable topsheet, b) acontainment member joined to the topsheet, c) an absorbent core disposedbetween said containment member and said topsheet, said absorbent corehaving opposing longitudinal edges; wherein the containment membercomprises opposing upstanding edges and an elastic member joinedproximate to the upstanding edge such that said elastic member lifts aportion of the containment member away from the body-facing surface ofthe absorbent assembly during wear of the absorbent article, wherein thecontainment member comprises: i) a central zone disposed between theabsorbent core and the garment body, ii) a bond zone disposed adjacentto the elastic member, and iii) a barrier zones disposed between thecentral zone and the opposing upstanding edges of the containmentmember; wherein the central zone has a greater air flow according to theAir Permeability Test than the barrier zone; wherein the bond zone has agreater hydrohead according to the Hydrostatic Head Pressure Test thanthe barrier zone. 21) An absorbent article comprising a garment body andan absorbent assembly joined to the garment body such that the absorbentassembly is disposed between the garment body and a wearer during wear,wherein the garment body consists essentially of a liquid permeablematerial, wherein said absorbent assembly has a garment-facing surfaceand a body-facing surface, wherein said absorbent assembly comprises: a)a liquid permeable topsheet, b) a containment member comprising acontinuous substrate, and c) an absorbent core disposed between saidcontainment member and said topsheet, said absorbent core havingopposing longitudinal edges; wherein the containment member comprisesopposing upstanding edges and an elastic member joined proximate to theupstanding edges such that said elastic member lifts a portion of thecontainment member away from the body-facing surface of the absorbentassembly during wear of the absorbent article, wherein the containmentmember comprises: i) a central zone disposed between the absorbent coreand the garment body, ii) a pair of barrier zones disposed between thecentral zone and the opposing upstanding edges of the containment memberwherein the central zone has a greater air permeability than the barrierzone and the barrier zone has a greater hydrohead than the central zone.